Riello G5R MC Quick start guide

20013743 (3) - 04/2011
Installation, use and maintenance instructions
安装 , 使用以及维护说明书
Light oil burner
轻油燃烧器
CODE - 编码 MODEL - 型号 TYPE - 类型
20013623 G5R MC 447T1
GB
CN
One stage operation
一段火运行

20013743
GB
INFORMATION ABOUT THE INSTRUCTION MANUAL
INTRODUCTION
The instruction manual supplied with the burner:
- is an integral and essential part of the product and must not be sepa-
rated from it; it must therefore be kept carefully for any necessary
consultation and must accompany the burner even if it is transferred
to another owner or user, or to another system. If the manual is lost
or damaged, another copy must be requested from the Technical
Assistance Service of the area;
- is designed for use by qualified personnel;
- offers important indications and instructions relating to the installation
safety, start-up, use and maintenance of the burner.
DELIVERY OF THE SYSTEM AND THE INSTRUCTION MAN-
UAL
When the system is delivered, it is important that:
- The instruction manual is supplied to the user by the system manu-
facturer, with the recommendation to keep it in the room where the
heat generator is to be installed.
- The instruction manual shows:
- the serial number of the burner;
- the address and telephone number of the nearest Assistance
Centre;
- The system supplier carefully informs the user about:
- the use of the system,
- any further tests that may be necessary before the system is
started up,
- maintenance and the need to have the system checked at least
once a year by the manufacturer or another specialised techni-
cian.
To ensure a periodic check, recommends the drawing up
of a Maintenance Contract.
..................................................................................
..................................................................................
..................................................................................
..................................................................................

1 20013743
GB
TECHNICAL DATA
BURNER DESCRIPTION
OBurner with CE marking in conformity with EEC Directives: EMC 2004/108/EC, Low Voltage 2006/95/EC,
Machines 2006/42/EC.
OThe burner meets protection level of IP 40, EN 60529.
HYDRAULIC JACK OPERATION 7)(Fig. 1)
TYPE 447T1
Thermal power – output 28 – 60 kW – 2.3 – 5 kg/h
Fuel Light oil, viscosity 4 – 6 mm2/s at 20 °C
(Hi= 11.86 kWh/kg)
Electrical supply Single phase, 230V ±10% ~50Hz
Motor Run current 0.75A – 2800 rpm – 294 rad/s
Capacitor 4 F
Ignition transformer Secondary 8 kV – 16 mA
Pump Pressure 7 – 15 bar
Absorbed electrical power 0.185 kW
It is strongly recommended a periodic check of the pump pressure operation (annually or better every six
months, if the burner operation is continuous).
If the value is lower than 1 bar, compared to that one of the initial setting, please check the cleaning of the
pump and line filters.
In case the pressure setting was not restorable, please replace the pump, in order to guarantee that the
pump pressure during the pre-purge time is at least 3.7 bar.
1– Return line
2– Suction line
3– Gauge connection
4– Pump pressure regulator
5– Vacuum gauge connection
6– Screws fixing air damper
7– Hydraulic jack with air damper
8– Lock-out lamp and reset button
9– Flange with insulating gasket
10 – Combustion head adjustment screw
Fig. 1
5
D4645 1243
6
6
7
9
108
DANGER

20013743 2
GB
BURNER EQUIPMENT
Flexible pipes with nipples . . . . . . . . . . . No. 2 Cover . . . . . . . . . . . . . . . . . . . . . . . No. 1
Screws and nuts for flange . . . . . . . . . . . No. 4 Hinge . . . . . . . . . . . . . . . . . . . . . . . . No. 1
Screw with two nuts for flange . . . . . . . . No. 1 Insulating gasket . . . . . . . . . . . . . . . No. 3
FIRING RATE
OVERALL DIMENSIONS
0.8
0
0.4
Pressure in the combustion
chamber – mbar
2 3 4 5 Light oil output - kg/h
25 30 60 Thermal power - kW
D5226 35 40 45 50 55
0.2
0.6
2.3
270 122 224
130
=
33
45°
ø80
228
11
175
D4646
=
180
75 72
150
45°
Flange Burner

3 20013743
GB
MOUNTING THE BURNER
It is necessary that the insulating gasket
(9, fig. 1) is placed between the boiler door
and the burner flange.
This insulating gasket has six holes,
which, if necessary, can be modified as
shown on the drawing on the right.
D5242
Fig. 2
Verify that the installed
burner is lightly leaned
towards the button.
(See figure 2).
D5572
BURNER FIXING AND
HINGE ASSEMBLY
S7384

20013743 4
GB
HYDRAULIC SYSTEMS
Warning: before starting the burner make sure that the return pipe-line is not clogged: any obstruction
would cause the pump seals to break.
The pump vacuum should not exceed a
maximum of 0.4 bar (30 cm Hg).
Beyond this limit gas is released from
the oil.
Oil lines must be completely airtight.
The return line should terminate in
the oil tank at the same level as the
suction line; in this case a non-return
valve is not required.
When the return line arrives over the
fuel level, a non-return valve must be
used.
This solution however is less safe than
previous one, due to the possibility of
leakage of the valve.
PRIMING THE PUMP
Start the burner and wait for the priming.
Should lock-out occur prior to the arrival
of the fuel, await at least 20 seconds
before repeating the operation.
A filter must be installed on the suction fuel line.
H
meters
Lmeters
I. D.
8 mm I.D. 10 mm
0.5
1
1.5
2
10
20
40
60
20
40
80
100
WARNING
The pump is supplied for use with a two pipe system.
For use on a one pipe system, it is necessary to remove the by-pass
screw (A, fig. 3).
A
H
meters
Lmeters
I. D.
8 mm I.D. 10 mm
0
0.5
1
1.5
2
3
3.5
35
30
25
20
15
8
6
100
100
100
90
70
30
20
H max. 4 m
H
H
max. 4 m
min. 0.1 m
D5219
D5220
D5199
H=Difference of level.
L=Max.length of the
suction line.
I.D.=Internal diameter of the
oil pipes.
PRIMING THE PUMP
Loosen the plug of the vacuum gauge (5, fig. 1,
page 1) and wait until the fuel flows out.
Fig. 3

5 20013743
GB
ELECTRICAL WIRING
ATTENTION:
Do not swap neutral and phase over, follow the diagram
shown carefully and carry out a good earth connection.
The section of the conductors must be at least 1mm². (Unless re-
quested otherwise by local standards and legislation).
The electrical wiring carried out by the installer must be in
compliance with the rules in force in the country.
CONTROL BOX, (see fig. 4)
To remove the control box (1) from the burner:
Unscrew the fissing screws on the burner cover and remove it.
Unscrew the fissing screws (2) on the plate and remove the
control box (1).
Screw the two fissing screws (2) and reassemble the burner
cover.
Fix the control box (1) with plate far from the burner.
TESTING
Check the shut-down of the burner by opening the thermostats.
21
D4677
Key to lay-out
A- Control box 531SE
C- Capacitor
E- Electrode
F-Fuse
FR -P.E.Cell
H- Lock-out signal
I- Main switch
M-Motor
PE - Burner-earth
R- Heater
TL - Limit thermostat
TS - Safety thermostat
Y- Oil valve
Fig. 4

20013743 6
GB
COMBUSTION ADJUSTMENT
In conformity with Efficiency Directive 92/42/EEC the application of the burner on the boiler, adjust-
ment and testing must be carried out observing the instruction manual of the boiler, including verifica-
tion of the CO and CO2concentration in the flue gases, their temperatures and the average
temperature of the water in the boiler.
To suit the required appliance output, fit the nozzle then adjust the pump pressure, the setting of the
combustion head and the air damper opening in accordance with the following table.
The values shown in the table are measured on a CEN boiler (as per EN 267).
They refer to 12.5% CO2at sea level and with light oil and room temperature of 20 °C.
RECOMMENDED NOZZLES: Monarch type R - NS; Delavan type W - A - E;
Steinen type H - Q; Danfoss type H.
Angle:60°:in most cases.
80° : in case of flame detachment, during ignitions at low temper-
atures.
PUMP PRESSURE 12 bar : the pump leaves the factory set at this value
14 bar : improves flame retention; it is therefore suitable for ignitions
at low temperatures.
COMBUSTION HEAD SETTING
This is done when fitting the nozzle, with the blast
tube removed. It depends on the output of the
burner and is carried out by rotating the regulating
rod, till the terminal plane of the blast tube is level
with the set-point, as indicated in the table.
In the figure 5, the combustion head is set for an
output of 0.75 GPH at 12 bar, while the shutter is
level with set-point 2.5, as required by the above
table.
Nozzle Pump pressure Burner output Comb. head
adjustment Air damper adjustment
GPH Angle bar kg/h ± 4% Set-point Set-point
0.60 60°/80° 11 2.3 1.5 2
0.65 60°/80° 12 2.6 2 2.2
0.75 60° 12 3.0 2.5 2.5
0.85 60° 12 3.4 3 3
1.00 60° 12 4.0 4 4.5
1.10 60° 12 4.4 5 6
1.25 60° 12 5.0 6 7
SETTINGS CARRIED OUT IN THE FACTORY
0.75 60° S 12 3.0 2.5 2.5
1
2
3
4
1
2
D5582
2
135
Blast tube
Regulating rod
Shutter
Terminal plane of the blast tube
Fig. 5
3

7 20013743
GB
Combustion head settings indicated in the table are valid
for most cases. The setting of the fan output according to
the installation should normally be done only through the
air damper. Should one subsequently want to retouch
also the setting of the combustion head (fig. 6), with the
burner running, operate on the rod (1) with a 6 mm span-
ner (2) as follows:
Turn to the right: (sign +):
In order to increase the volume of air entering the com-
bustion chamber and thus diminishing its pressure.
There is a reduction of CO2and the adhesion of the
flame to the air diffuser disc improves. (Setting advisable
for ignitions at low temperatures).
Turn to the left: (sign –):
In order to reduce the volume of air entering the combus-
tion chamber and thus increasing its pressure. The CO2
improves and the adhesion of the flame to the diffuser
tends to reduce. (This setting is not advisable for igni-
tions at low temperatures).
In any case do not bring the combustion head setting
more than one point away from that indicated in the
schedule. One set-point corresponds to 3 turns of the
rod; a hole (3) at its end facilitates counting the number
of turns.
AIR DAMPER ADJUSTMENT, (fig. 7)
The mobile air damper (A) operated by the jack (B) as-
sures the complete opening of the air intake.
The regulation of the air-rate is made by adjusting the
fixed air damper (C), after loosing the screws (D).
When the optimal regulation is reached, screw tight the screws (D) to assure a free movement of
the mobile air damper (A).
The settings indicated in the table refer to the burner with its metal cover fitted and the combustion
chamber with “zero” depression.
These regulations are purely indicative.
Each installation however, has its own unpredictable working conditions: actual nozzle output;
positive or negative pressure in the combustion-chamber, the need of excess air, etc.
All these conditions may require a different air-damper setting.
It is important to take account of the fact that the air output of the fan differs according to
whether the burner has its metal cover fitted or not.
Therefore we recommended to proceed as follows:
– adjust the air damper as indicated in the table;
– mount the cover, simply by means of the upper screw;
– check smoke number;
– should it become necessary to modify the air output, remove the cover by loosening the screw,
adjust the air damper, remount the cover and finally recheck the smoke number.
1
23
6
D5551
D
C
D5555
D
AB
Fig. 6
Fig. 7
4

20013743 8
GB
FUEL HEATING
In order to obtain smooth starting and operation across
its output range the burner is fitted with an electric
resistance, which heats up the gas oil in the nozzle
line. This resistance is energized when the thermostat
calls for heat and after a delay of approximately two
minutes depending on room temperature, the motor
will start. The resistance remains inserted and locks-
out on the shut-down of the burner.
Attention
Should you want to cut off the electric resistance (on
setting the burner or when the ambient temperature
does not require it, etc. . .), take the plug off the panel
of the control box and plug it into the “Resistance
OFF” (see fig. 8). In this case the burner starts
up when the thermostats close.
NOTE
The warning light (LED) is ON but when the resist-
ance works. It is OFF when the resistance is discon-
nected or broken.
FAILURE DETECTION ON HEATING
DEVICE - Only for type 447T1
The plug fitted in the panel is placed in the position corre-
sponding to “Resistance ON” (see fig. 8).
When the remote control closes, the LED lights up and,
after about two minutes, the burner starts up.
1) If the LED is OFF, the heating resistance placed
in the nozzle-holder is off.
2) If the LED is ON and nevertheless the burner does not run, place the plug in the position corre-
sponding to “Resistance OFF” (see fig. 9). If the motor runs, the delaying device inside
the control box is out of order.
3) If the motor does not run, it means that the failure is neither in the panel nor in the resistance, but
elsewhere.
ELECTRODE SETTING, (see fig. 10)
PLUG
Resistance ON
Resistance OFF LED
S7059
Control box
531SE B
PLUG
Resistance OFF
S7060
LED
Fig. 8
Fig. 9
NORMAL OPERATION
BURNER DOES NOT OPERATE
IMPORTANT:
THESE DIMENSIONS MUST BE
OBSERVED
Before removing or assembling the
nozzle, loosen the screw (A) and
move the electrodes ahead.
2 – 2.5 mm
4± 0.3 mm
D5230 A
Fig. 10

9 20013743
GB
BURNER START-UP CYCLE
WARNINGS TO AVOID BURNOUT OR BAD COMBUSTION OF THE BURNER
– When the burner is stopped, the smoke pipe must be opened and effect a natural draught in the
combustion chamber. If the smoke pipe is closed, the burner must be drawn back till the extrac-
tion of blast tube from the furnace. Before operating in this way take the voltage off.
– The place, where the burner works, must have same openings suitable for the passage of air nec-
essary for combustion. To be sure about this, you have to control the smoke number of exhaust
gas with all the windows and doors closed.
– If in the place, where the burner works, there are air-breathings, check the existence of air-input
openings with dimensions suitable for the necessary air-exchange. In any case check that, when
the burner is stopped, the air-breathings do not draw warm smokes from pipes through the
burner.
Normal Lock-out, due to light-failure
Thermostat
Heater
Motor
Ignition transformer
Valve
Flame
~120s D5329 ~120s ~12s
Lock-out lamp
~12s ~5s

20013743 10
GB
MAINTENANCE
The burner requires periodic maintenance carried out by a qualified and authorised technician in con-
formity with legislation and local standards.
Periodic maintenance is essential for the reliability of the burner, avoiding the excessive consump-
tion of fuel and consequent pollution.
Before carrying out any cleaning or control always first switch off the electrical supply to
the burner acting on the main switch of the system.
THE BASIC CHECKS ARE:
Check there are no occlusions or obstructions in the inlet or return pipes, in the air suction areas and
in the combustion product waste pipe.
Clean the filter in the oil suction line and in the pump.
Check for correct fuel consumption.
Check that the burner electrical connections are correct.
Replace the nozzle and check the correct position of electrodes.
Clean the combustion head in the fuel exit area.
Check that the positioning of the combustion head is correct and that it is properly fixed to the
boiler.
Check that the air damper is positioned correctly.
Let the burner run at full capacity for about ten minutes, setting all the elements correctly as explained in
this manual. Then carry out the analysis of the combustion by checking:
- Smoke index as per the Bacharach scale; - CO2percentage (%); - CO content (ppm);
- NOx content (ppm); - Smoke temperature at the chimney.

20013743
CN
说明书的相关信息
引言
说明书随燃烧器一起提供：
- 它是产品不可或缺的组成部分，不得将其与产品分离；因此必须小心
保存以便查阅，如果将燃烧器转给另一个用户或转移至另一个系统，
则说明书必须跟随燃烧器一起转移。如果说明书损坏或丢失，则必须
从您就近的 Technical Assistance Centre （技术支持中心）
索取说明书的复印件；
- 说明书只能由有资格的人员使用；
- 说明书提供了有关燃烧器安装、启动、使用和维护的重要指示和安全
警告。
系统和说明书的交付
一旦交付系统：
- 系统制造商也必须将说明书交付给用户，并建议其将说明书保存在热
发生器的安装区域附近。
- 说明书上显示：
- 燃烧器的序列号；
- 最近 Assistance Centre （支持中心）的地址和电话号码；
- 系统制造商必须告知用户有关以下内容的准确信息：
- 系统的使用；
- 启动系统前需要进行的测试；
- 必需的维护和检查 （每年必须由制造商代表或别的专业技术人员至少
检查系统一次）。
要保证定期检查， 建议遵照 Maintenance Contract （维护合同）
的规定。
..............................................
..............................................
..............................................
..............................................

1 20013743
CN
技术参数
燃烧器说明
O带CE 标志的燃烧器满足如下 EEC 指令： EMC 2004/108/EC，低压 2006/95/EC，机械 2006/42/EC。
O燃烧器符合 EN 60529 标准的 IP 40 保护等级。
液压千斤顶运作方式 7)( 图 1)
型号 447T1
燃烧器出力 28 – 60 kW – 2.3 – 5 kg/h
燃料 轻油 , 20 °C 时的最大黏度 :4- 6 mm2/s (1.5°E)
(Hi= 11.86 kWh/kg)
电源 单相 , 230V ±10% ~50Hz
电机 运行电流 0.75A – 2800 rpm – 294 rad/s
电容 4 F
点火变压器 次级 8 kV – 16 mA
油泵 压力 : 7 – 15 bar
耗电量 0.185 kW
强烈建议周期性地检查泵压力是否正常运作 （每年一次，或者在燃烧器不断运行的情况下，建议检查的时
间为六个月一次）。
如果压力值比初始设定值小 1 巴， 检查泵和线路中的过滤器是否干净。
如果压力无法复位， 请更换泵以便保证预吹扫过程中，压力至少为 3.7 巴。
1–回油管
2–进油管
3–压力表接口
4–油压调压器
5–真空表接口接口
6–固定风门挡板的螺栓
7–控制风门挡板的液压装置
8–复位按钮和锁定指示灯
9–法兰和隔热垫
10 –燃烧头调整螺栓
图. 1
5
D4645 1243
6
6
7
9
108
危险

20013743 2
CN
燃烧器附件
带接头的软油管 . . . . . . . . . . . . . . . . . . . . . . 2 根盖. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 个
螺栓并带 2 个螺帽 . . . . . . . . . . . . . . . . . . . . 4 套铰链. . . . . . . . . . . . . . . . . . . . . . . . . . 1 副
螺栓并带 2 个螺帽 . . . . . . . . . . . . . . . . . . . . 1 套隔热垫. . . . . . . . . . . . . . . . . . . . . . . . 3 个
负荷图
外观尺寸
0.8
0
0.4
炉膛背压 -mbar
2345轻油喷油量 - kg/h
25 30 60 燃烧器出力 - kW
D5226 35 40 45 50 55
0.2
0.6
2.3
270 122 224
130
=
33
45°
ø80
228
11
175
D4646
=
180
75 72
150
45°
法兰 燃烧器

3 20013743
CN
安装燃烧器
在燃烧器法兰和锅炉炉门之间必须安装隔热
垫(9,图.1)。
隔热垫有 6 个孔，如有必要可按右图图示调节
这 6 个孔。
D5242
图. 2
检查安装好的燃烧器，确保燃
烧器如图示略微倾斜(图. 2)。
D5572
燃烧器固定和铰链组件
S7384

20013743 4
CN
油路系统
警告 :启动燃烧器前确保回油管路畅通：
回油管路堵塞可能造成油泵密封损坏。
油泵真空度不能超过 0.4 bar (30 cm Hg)。
超过此限值会导致油气分离。油管路必须
密封不透气。
回油管必须插进油箱油面下，末端和进油
管在同一水平面上。
这种情况下可以不安
装止回阀。
回油管末端高出油面时，必须安装止回阀。
这种方法不如前一种安全，因为止回阀
存在泄漏的可能。
油泵注油
启动燃烧器等待油泵注油。如果油注入油
泵前发生锁定，至少等待 20 秒后再重复此
操作。
进油管上必须安装过滤器。
H
米
L米
内径
8 mm 内径 10 mm
0.5
1
1.5
2
10
20
40
60
20
40
80
100
警告
油泵用于双油管系统。如要单油管运行，必须拆卸掉旁路螺栓 (A，图 . 3)。
A
H
米
L米
内径
8 mm 内径 10 mm
0
0.5
1
1.5
2
3
3.5
35
30
25
20
15
8
6
100
100
100
90
70
30
20
H最大 4 m
H
H
最大 4 m
最小 0.1 m
D5219
D5220
D5199
H=液面高度差。
L=进油管最大长度。
I.D.=油管内径。
油泵首次启动
松开真空表接口上的螺栓 (5, 图.1, 第1 页)直到有油
溢出。
图. 3

5 20013743
CN
电气接线图
注意：
不要把火险和零线接反，按图仔细接线并保证接地良好。
使用横截面面积不小于 1mm² 的电缆。(
除非根据本地法规或标准
有其它要求
) 。
电气接线必须由有资格人员执行，必须遵守本国现行的法规和规
范。
控制盒， (见图 . 4)
按如下步骤从燃烧器上拆卸控制盒 (1)：
松开燃烧器盖上的固定螺栓并拆下盖子。
松开固定控制盒的固定螺栓 (2) 并拆下控制盒 (1)。
拧紧两颗固定螺栓 (2) 并装回燃烧器机盖。
从燃烧器侧装回控制盒 (1)。
测试
断开温控开关检查燃烧器是否停机。
21
D4677
图例说明
A-控制盒 531SE
C-电容
E-点火电极
F-保险丝
FR -P.E.电眼
H-锁定信号
I-主开关
M-电机
PE -燃烧器接地
R-加热器
TL -启动温控开关
TS -安全温控开关
Y-油阀
图. 4

20013743 6
CN
燃烧调整
根据效率指令 92/42/EEC 对于使用在锅炉上的燃烧器，调整和测试必须根据锅炉的使用说明书来执行，包括
检验烟气中 CO 和CO2的含量，烟气温度和锅炉内热水的平均温度。
为使燃烧器达到额定的出力，首先安装好合适的喷嘴，然后根据下表对燃烧头的位置和风门挡板开度进行设
置。
下表中的值在 CEN 锅炉上测试得到 ( 根据欧盟燃油燃烧器 EN 267 标准 )。
测试条件为 CO2浓度为 12.5%，海平面高度，轻油，室温 20°C。
推荐使用的喷嘴 :Monarch R - NS 型； Delavan W - A - E 型；
Steinen H - Q 型； Danfoss H 型。
雾化角 :60°:适应于多数情况。
80° : 适应于火焰分离，或低温点火情况。
油泵压力 12 bar : 出厂时的设置值。
14 bar : 提高火焰稳定性；也适应于低温点火情况。
燃烧头的设置 :
安装喷嘴时设置，先拆下燃烧筒。
根据燃烧器最大出力来设置（如上表所示），通过旋转调
节杆来设置，直到燃烧筒的端面与设定 值刻度对齐。
图5中，燃烧头为 12bar 时 0.75 GPH 的出力而设
置，按上表要求，此时内风筒应设置在 2.5。
喷嘴 油泵压力 燃烧器出力 燃烧头调整 风门挡板调整
GPH 雾化角 bar kg/h ± 4% 设置点 设置点
0.60 60°/80° 11 2.3 1.5 2
0.65 60°/80° 12 2.6 2 2.2
0.75 60° 12 3.0 2.5 2.5
0.85 60° 12 3.4 3 3
1.00 60° 12 4.0 4 4.5
1.10 60° 12 4.4 5 6
1.25 60° 12 5.0 6 7
出厂设置值
0.75 60° S 12 3.0 2.5 2.5
1
2
3
4
1
2
D5582
2
135
燃烧筒
调节杆
内风筒
燃烧筒末端面
图. 5
3